METHOD FOR PRODUCING CORRUGATED MATERIAL
This invention relates to a method for producing corrugated material and processing strip material which is removed from the edges of the corrugated material during the formation process. The strip material is cut away from the corrugated material and expelled at a variable line speed to a trim processing machine. The line speed is measured by a sensor which provides a signal representation of the speed to a cutter assembly. The cutter assembly cuts the strip material at a cutting speed which is sequenced to the line speed such that the strip material is cut into a plurality of pieces. The pieces are generally uniform in shape and size across variations in the line speed as the cutting speed is synchronized with the line speed.
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1. Technical Field
The invention relates generally to a method for producing corrugated material. More particularly, the invention relates to a method for forming corrugated material by cutting the edges off the corrugated material into a strip material, and then processing the strip material into smaller pieces at a variable processing speed. Specifically, the invention relates to a method for varying the processing speed in response to variations in the input speed of the strip material, such that the strip material is continuously converted into a plurality of smaller pieces having the same generally uniform shape.
2. Background Information
This invention relates to the process of making corrugated material, forming the material into boxes or other similar commercial products, and processing the waste edge strip material of this process into a new commercial product. Previously, the waste edges of this process were discarded as unusable.
Paper based corrugated material is formed in a corrugator and fed directly into an edge cutter. The edge cutter cuts the corrugated material to a specified width to match the size requirements for the particular commercial product being produced. The edge strip material is cut away and the corrugated material travels on to be formed into the finished product. As the strip material comes out of the edge cutter, it is either fed into a bin for later processing, or fed into a trim processing machine (“trim cutter”) whereby the long narrow pieces are cut into smaller pieces by a blade. After this cutting stage, the cut strip material is collected, baled, and processed as waste by-product of the corrugation process.
Trim processing machines to date include a blade which simply cuts across the width of the strip material at a static interval, regardless of the speed with which the strip material enters the trim processing machine. This static cutting frequency results in large pieces when the strip material moves through the machine at a fast rate, and small pieces when the strip material moves through the machine at a slow rate. Furthermore, trim processing machines and methods to date cannot match the fast line speeds of the corrugator and edge cutter. Therefore the strip material typically is collected after exiting the edge cutter, and later fed into the trim processing machine.
Heretofore, existing trim processing machines and methods have been characteristically inefficient and lacking in processing the waste edge strip material during the formation of the corrugated product. Therefore, the need exists for a trim processing method which can match the fast line speeds of the corrugator so the strip material may be processed at the same time the corrugator is forming the commercial product. There is also a need to cut the strip material at a cutting frequency which is sequenced or matched with the speed of the corrugator line and edge cutter, thereby allowing uniformly sized pieces of the cut strip material to be produced across the entire range of possible input speeds which may dynamically change during operation. The need also exists for a trim processing method which cuts across both the length and width of the strip material to produce cut trim pieces which are smaller than the overall width of the trim.
If a manufacturer of corrugated products could produce a uniformly sized by-product of the corrugation process, regardless of the line speed or width of the strip material, the cut strip material pieces could be resold as a commercial product and used various applications such settings as animal bedding. This represents an enormous improvement in the field, as currently scrap strip material pieces are simply discarded.
BRIEF SUMMARY OF THE INVENTIONThis invention focuses on a method for producing corrugated material and processing the strip material expelled as a by-product of the production process at a variable line speed. The method of the present invention utilizes a corrugator having a flute processing device for producing a fluted sheet, and a backer device to apply a liner to the fluted sheet and expel a corrugated material at a line speed. The expelled corrugated material is then received by an edge cutter machine, wherein edge strip material is cut off the edges of the corrugated material. This edge strip material is subsequently fed into a trim cutting machine. The trim cutting machine is generally comprised of a sensor for measuring the line speed, a cutter assembly which is operatively connected to the sensor, and a feeder assembly which is also operatively connected to the sensor. The feeder assembly receives the strip material from the edge cutter machine and conveys the strip material to the cutter assembly at the line speed. The cutter assembly cuts the strip material at a cutting speed into a plurality of pieces having a uniform size and shape and collects the pieces for eventual commercial use. This uniform shape is ensured by varying the cutting speed in response to variations of the line speed. It is readily understood that the edge cutter machine may exist as a sub-machine within the overall corrugator machine, or may exist separately.
The feeder assembly preferably used in the present method has a plurality of first bumpers disposed within a housing, and a plurality of second bumpers disposed within the housing, whereby the first and second bumpers rotationally cooperate to convey the strip material therethrough. The feeder assembly further includes a motor, whereby the motor is operationally connected to the sensor, and the first and second bumpers are rotationally controlled by the motor. The motor then rotates the bumpers to match the line speed and thereby convey the strip material through the housing to the cutter assembly at the line speed.
The cutter assembly preferably used in the present method has at least one rotor having a plurality of blade assemblies disposed thereon, a motor, and an anvil having a teeth portion. The blade assemblies each includes a blade portion complementarily shaped with the teeth portion. The rotor is rotated by the motor at the cutting speed to engage the blade portion with the teeth portion to cut the strip material.
A preferred embodiment of the invention, illustrated of the best mode in which Applicant contemplates applying the principles, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.
Similar numbers refer to similar parts throughout the drawings.
DETAILED DESCRIPTION OF THE INVENTIONThe preferred machine for carrying out the steps of processing strip material of the present invention is indicated generally at 1, and shown in
The general machine and system for turning raw materials into corrugated material is shown diagrammatically in
Raw corrugated sheet 21 exits backer device 17 in the direction of Arrow D at a variable speed and comprises a raw corrugated material having a width which corresponds to the width of materials 7, 15, and 25. A sensor 26 is located proximate backer device 17 and measures the speed with which raw corrugated sheet 21 exits the backer device. Sensor 26 passes the speed information to trim processing machine 1 through a conductor 28. Next, raw corrugated sheet 21 is fed into an edge cutter 29 which cuts an elongate pair of trim edges 31 off raw corrugated sheet 21 to form a finished corrugated sheet 33. Finished corrugated sheet 33 conforms to the particular width requirement of the intended product, and is carried away by a conveyer belt 35 or other transport mechanism in the direction of Arrow E for further processing. Trim edges 31 exit edge cutter 29 and enter trim processing machine 1 in the direction of Arrow F. Trim processing machine 1 performs processing functions therein at a particular speed based on the signal supplied by sensor 26 through conductor 28, and expels a plurality of uniform cut pieces 37 (
As shown in
Feeder sub-assembly 49A further includes an adjustable first roller system 77 and a non-adjustable second roller system 78, both of which are driven by a drive shaft 83. Drive shaft 83 is powered by a drive belt 79 extending from a drive motor 81. Drive shaft 83 extends the width of sub-assembly 49A (
Non-adjustable second roller system 78 (
A pair of alignment rods 90 (
As shown in
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As shaft 131 turns, rotors 165A and 165B turn to pass blades 173 through a pair of complementarily shaped anvils 179 as each blade assembly 168 rotates past anvils 179. As shown in
As shown in
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As shown in
As trim edges 31 enter trim processing machine 1 in the direction of Arrow F (
Rotor 165A is rotated at a speed such that when trim edge 31 is conveyed over anvil 179 at the line speed, one of the plurality of blade plates 171 rotates through anvil 179 at precisely the moment to cut trim edge 31 into the desired uniform size pieces 37. As the line speed increases, the rotational speed of rotor 165A increases to continue processing trim edges 31 into the desired uniform size pieces 37. Likewise, as the line speed decreases, the rotational of rotor 165A decreases to continue processing trim edges 31 into the desired uniform size. The uniform size of pieces 37 is considerably smaller in length and width than the original length and width of trim edges 31.
A user may configure the specific size of uniform pieces 37 by replacing anvils 179 and blade plates 171. This is achieved by removing access panels 163 and unsecuring blade plates 171 from blade holders 169. Similarly, anvils 179 may be unsecured from anvil mount 146 and replaced. Thus, blade plates 171 may include differently sized recesses 174 and blades 173, corresponding to anvils 179 having complementarily sized recesses 181 and teeth 183.
As shown in
In operation, raw corrugated sheet 21 is formed in corrugator 3 as discussed above where it is fed into edge cutter 29 at a particular line speed. The line speed changes depending on the particular job requirements and flute size. Sensor 26 is positioned to read the speed with which raw corrugated sheet 21 exits corrugator 3, and continuously relays this information to trim processing machine 1 via conductor 28. As shown in
As shown in
As pieces 37A and 37B fall away, bumpers 97 and 111 continue to convey trim edges 31 into cutter assembly 45 at the line speed. The required length of trim edge 31 is continuously conveyed over anvil 179 in time for the subsequent blade assembly 168 rotate past anvil 179. If the line speed increases, sensor 26 relays this change to motors 81 and 123, which react accordingly to maintain cutting synchronization with the line speed. Thus, the process of shearing trim edge 31 into pieces 37A and 37B is continuous and precise to generate uniform pieces 37 of trim through dynamic changes in the line speed. Cut pieces 37 fall downward away from anvil 179 and travel out of cutter assembly 45 through channel 158 in the direction of Arrow K into duct 39. Duct 39 directs pieces 37 into hopper 41 where they are collected and bundled for future use.
It is commercially desirable to guarantee a particular size and shape of corrugated pieces expelled from trim processing machine 1. As trim edges 31 are processed into a guaranteed uniform size and shape in trim processing machine 1, independent of the line speed, pieces 37 may readily be bundled and sold as a new product. This represents an improvement in the art, as a new commercial product is created from what was considered previously by the industry to be a waste by-product of the corrugation process. The uniform size may be altered by replacing anvil 179 and blade plate 171, which allows the user to custom tailor the piece sizes for a particular industry or buyer. For example, uniform pieces of corrugated material having a specific size are especially desirable in the equine industry because these uniform pieces 37 cannot become embedded into the animal's hoofs. Furthermore, the low weight pieces 37 are easily shoveled out of the animal stall after use. However, it will be readily understood that the novelty of the present invention extends generally to all strip material, and is not limited to corrugated material.
It will be readily understood that conductor 28 could consist of a wireless communication system, whereby the line speed information is provided to motor 81 and motor 123 wirelessly, or by any other common communication system. Likewise, it will be readily understood that trim edges 31 may be fed directly into a cutter assembly during the corrugation process. However, the preferred embodiment includes a feeder assembly.
In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.
Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described.
Claims
1. A method for producing corrugated material comprising:
- forming a corrugated sheet at a line speed;
- removing a strip material from an edge of the corrugated sheet at the line speed;
- feeding the strip material into a cutter assembly at the line speed;
- providing a sensor operatively connected to the cutter assembly for measuring the line speed;
- cutting the strip material at a cutting speed into a plurality of pieces having a uniform size;
- synchronizing the cutting speed with the line speed, whereby variations in the line speed results in variations in the cutting speed; and
- maintaining the uniform size through variations in the line speed.
2. The method of claim 1, further comprising the steps of:
- cutting the strip material in a first direction; and
- cutting the strip material in a second direction, whereby the second direction is different from the first direction.
3. The method of claim 2, whereby the first direction and the second direction are generally perpendicular to each other.
4. The method of claim 1, further comprising the steps of:
- providing a blade plate having a plurality of blades in the cutter assembly;
- providing an anvil having a plurality of teeth in the cutter assembly; and
- engaging the blades with the teeth, whereby the blades and teeth cooperate to cut the strip material.
5. The method of claim 4, further comprising the step of arranging the blades and teeth in a complementary sawtooth pattern.
6. The method of claim 4, further comprising the steps of:
- providing a rotor in the cutter assembly;
- securing a plurality of blade holders to the rotor;
- removably securing blade plates to each blade holder to form a plurality of blade assemblies; and
- rotating the rotor to successively engage the blades of each blade plate with the teeth, whereby the blades and teeth cooperate to cut the strip material.
7. The method of claim 6, further comprising the steps of:
- providing a motor to rotate the rotor;
- operatively connecting the sensor to the motor; and rotating the rotor to cut the strip material at the cutting speed.
8. The method of claim 7, further comprising the steps of:
- providing a feeder assembly to convey the strip material into the cutter assembly;
- operatively connecting the feeder assembly to the sensor; and conveying the strip material from the feeder assembly to the cutter assembly at the line speed.
9. The method of claim 8, further comprising the steps of:
- providing a housing in the feeder assembly;
- providing a plurality of first bumpers in the housing;
- providing a plurality of second bumpers in the housing; and
- rotating the first and second bumpers to convey the strip material therethrough and into the cutter assembly at the line speed.
10. A method for processing corrugated material comprising:
- forming a fluted sheet of material;
- adhering a top liner to the fluted sheet of material and a bottom liner to the fluted sheet of material, thereby forming a sheet of corrugated material at a line speed;
- providing a sensor for measuring the line speed;
- trimming at least one edge from the sheet of corrugated material into an elongated piece of strip material;
- operatively connecting the sensor to a cutter assembly, whereby the sensor communicates the line speed to the cutter assembly;
- conveying the strip material into the cutter assembly at the line speed in a generally first direction;
- cutting the strip material into a plurality of pieces having a uniform size; and
- synchronizing the cutting speed with the line speed to maintain the uniform size through changes in the line speed.
11. The method of claim 10, further comprising the steps of increasing the cutting speed when the line speed increases; and decreasing the cutting speed when the line speed decreases.
12. The method of claim 10, further comprising the steps of:
- forming the fluted sheet of material with a plurality of flutes from a first material; and
- adhering a second material and a third material to the fluted sheet, thereby producing the sheet of corrugated material.
13. The method of claim 10, further comprising the steps of cutting the elongated piece of strip material in the first direction; and cutting the said elongated piece of strip material in a second direction, whereby the first direction and the second direction are generally perpendicular to each other.
14. The method of claim 10, further comprising the steps of:
- directing a stream of air through the cutter assembly; and
- directing the stream of air to convey the plurality of pieces out of the cutter assembly.
15. The method of claim 10, further comprising the steps of:
- trimming a first edge from the sheet of corrugated material into a first elongated piece of strip material;
- trimming a second edge from the sheet of corrugated material into a second elongated piece of strip material;
- providing a first rotor and a second rotor in the cutter assembly;
- cutting the first strip material with the first rotor and cutting the second strip material with the second rotor; and
- alternating cutting of the first strip material and second strip material.
16. The method of claim 15, further comprising the steps of:
- disposing a plurality of blades on the first rotor to cut the first strip material; and
- disposing a plurality of blades on the second rotor to cut the second material, whereby the plurality of blades on the second rotor are cross-sectionally intermediate the plurality of blades on the first rotor.
17. A method for processing a strip of edge material cut from a sheet of material into uniform pieces including the steps of:
- measuring the speed of the sheet of material as it enters an edge cutter machine which cuts at least one strip of the edge material from the sheet of material;
- feeding the strip of edge material into a trim processing machine having a feeder assembly and a cutter assembly;
- feeding the strip of edge material from the feeder assembly into the cutter assembly at a predetermined speed which is correlated to the speed of the sheet of material; and
- cutting the strip of edge material into a plurality of uniform pieces by a rotary cutter in the cutter assembly by correlating the speed of the rotary cutter to the speed of the sheet of material as it enters the edge cutter machine and to the speed of the strip of edge material in the feeder assembly.
18. The method of claim 17 including the steps of:
- cutting a pair of strips of the edge material from the sheet material in the edge cutting machine;
- providing the trim processing machine with a pair of the feeder assemblies and a pair of the cutter assemblies;
- providing each of the cutter assemblies with a rotary cutter, each cutter having a cutting blade; and
- synchronizing the speed of the rotary cutters whereby the cutting blades cut their respective strips of edge material at a different time.
19. The method of claim 17 including the step of providing the feeder assembly with a fixed roller system and an adjustable roller system; operatively interconnecting the fixed and adjustable roller systems with at least one drive belt; operatively connecting the fixed and adjustable roller systems with a drive motor; and controlling the speed of the drive motor by a sensor measuring the speed of the sheet of material.
20. The method of claim 19 including the step of providing each of the rotary cutters with a plurality of circumferentially spaced blades, each blade having a plurality of notches providing a saw tooth pattern to each of said blades.
Type: Application
Filed: Mar 26, 2010
Publication Date: Sep 29, 2011
Patent Grant number: 8460500
Applicant: GREIF PACKAGING LLC (Delaware, OH)
Inventors: Christopher A. Krumm (Akron, OH), Peter Watson (Dublin, OH), John M. Clifford (Mainville, OH)
Application Number: 12/732,948
International Classification: B32B 38/00 (20060101); B26D 1/34 (20060101); B26D 7/08 (20060101);